Thermal Joining

Joining technologies for e-mobility

An incomparable change is currently taking place in the field of mobility. When it comes to battery or hydrogen technologies, joining technology is faced with particular challenges in the production processes of such components. We offer novel solutions for non-ferrous metal alloys (e.g. copper, aluminum) and we can implement research activities for processes ready for series production, especially in the manufacturing of fuel cells, hydrogen storage systems and batteries.

Joining technologies for lightweight design

Lightweight design remains a key technology, especially in connection with the requirements of e-mobility. We offer the implementation of various developments:

• Joining technologies for multi-material design
• Joining technologies for FRP composites
• Technologies for new sustainable lightweight materials such as composites made of metal and natural substances

Machine learning and AI in joining technology

Due to the complex boundary conditions of thermal joining technologies, machine learning and and artificial intelligence have a high application potential. Today, it is possible to implement the first self-optimizing systems, especially in association with the latest systems for inline seam tracking and seam monitoring (such as OCT systems).

Efficiency in thermal joining technology

Maximum quality at minimal cost is one of the main demands of almost all production areas. This means that the processes have to be evaluated regularly:

• Holistic evaluation of process chains
• Evaluation and comparison of joining technologies
• Analysis of the latest developments
• Development of new joining strategies

Process analysis

The properties of joints are determined by various process factors. Modern methods and equipment are used for analyzing, modeling and optimizing welding processes.

Welding process and distortion simulation

Welding simulation is a standard tool that is used to calculate and optimize the welded joint, its metallurgical properties and dimensional accuracy.

Our offer includes

• Simulation for laser beam welding, arc welding and resistance pressure welding
• Determination of thermal fields
• Estimation of welding distortion and internal stress for punctate and linear welded joints

Damage analysis

Defective welded joints are a common cause of damage. Damage reports include damage mechanisms, repair concepts and concepts to avoid damage.

Suitable design for welding

Component design determines the most important boundary conditions for component production and the final component properties. Here, welding joints play a fundamental role.

Our support for your component design comprises

• CAD design (from the concept through prototyping and optimizing up to comparison of variants)
• Integration of welded joints
• Dimensioning and proof of strength according to current standards (DIN EN 1993 (EUROCODE 3), FKM guidelines, IIW recommendations
• Preparation of design documents and tests (especially with regard to the welding execution)

Simulation and optimization of components

• Interconnection of complex structures (CAD / FEM)
• Effect simulation (deformation, stress)
• Optimization of topology

Component and material properties

• Test of components and small samples
• Mechanical and thermal properties
  • Static stability
  • Fatigue behavior
  • Crash properties
• Corrosion properties
• Metallographic properties
• Determination of weld quality according to standards

Production concepts

• Development of specific production concepts
• Screening of joining technologies (systematic comparison of possible joining strategies)
• Development, establishment and testing of welding units

Laboratory implementation and research factory

• Virtual and real mapping of sub-processes
• Analysis of sensitivity
• Optimization of the process

Prototypes and test series

• Joining strategies for prototypes
• Design and manufacturing of prototype devices and jigs
• Manufacturing of production-oriented prototypes
• Analysis and evaluation of experiences (quality, dimensional accuracy, parameters, special features) for serial implementation

Industrial implementation

• Transfer of technologies to the enterprise
• Preparation of production files
• Production start-up supported by experts
• On-site training
• External monitoring of the production

Quality assurance

Development and implementation of holistic concepts of quality assurance (inline monitoring of each welding seam, documentation, self-optimization with the goal of zero-failure production)